Method for sealing a reusable electrical surgical instrument

ABSTRACT

A method for sealing surgical instruments, particularly reusable electric surgical instruments sterilized using an autoclave process, is disclosed. The method having the steps of providing at least two body shells having a runner system on the mating surfaces, aligning the body shells, securing the body shells in position relative to each other, inserting an injection device into the runner system, injecting an elastomer material from the injection device into the runner system, removing the injection device from the runner system, and curing the elastomer material. The elastomer material seals the housing chamber of the instrument. The elastomer material may bond the body shells together.

BACKGROUND

1. Technical Field

The present disclosure relates generally to reusable surgicalinstruments, and more particularly, to reusable electrical surgicalinstruments that are sterilized.

2. Description of Related Art

Electrical surgical instruments generally comprise of a handle portionhaving multiple body shells, which houses the electrical components, anda working portion extending from the handle portion, which comes incontact with a patient. After each use, an electrical surgicalinstrument is disposed of, reused, or partially disposed of andpartially reused. Any part of an electrical surgical instrument that isreused must be sterilized to neutralize potentially infectious agentsbefore being reused.

The autoclave process has been used for many years to sterilizedreusable surgical instruments. However, the steam and the high-pressureused in the autoclave process can damage electrical components withinthe housing. Even where the components are disposed in a shell, thecomponents can be damaged if the steam is allowed to infiltrate thejoints between the body shells of an electrical surgical instrument.Different sealing methods have been used to seal the joints between bodyshells.

One such sealing method is to bond the body shells of the handle portiontogether with adhesives. Another known method employs an o-ring that iscompressed between the body shells using screws or other joining means.

The existing sealing methods are known to fail after a varying number ofautoclave processes. One cause of the failure is that the sealingmaterials and the material of the body shells expand and contract atdifferent rates and to differing extents during the autoclave process.

Based on the above, a continuing need exists for a sealing method thatwill extend the life of reusable electrical surgical instruments capableof maintaining a sealed chamber during the contracting and expansionthat takes occurs during the autoclave process.

SUMMARY

Disclosed herein is a method for sealing body shells that injects anelastomer material into a runner system. The method includes the stepsof providing body shells of an instrument having a runner system,aligning the body shells, securing the body shells together, insertingan injection device into the runner system, injecting an elastomermaterial, removing the injection device, and curing the elastomermaterial forming a seal between the body shells.

In an embodiment of the method, the runner system forms ahalf-cylindrical groove on the joining surface.

In a certain embodiment of the method, the runner system is on bothjoining surfaces of a pair of mutual joining surfaces.

In another embodiment of the method, the elastomer material forms a bondbetween the body shells along the pair of mutual joining surfaces.

DESCRIPTION OF THE DRAWINGS

The above and other aspects, features, and advantages of the presentdisclosure will become more apparent in light of the following detaileddescription when taken in conjunction with the accompanying drawings inwhich:

FIG. 1 is a top plan view of a body shell having a runner system on thejoining surface;

FIG. 2 is an enlarged view of the area of detail 2 of FIG. 1;

FIG. 3 is a front cross-sectional view of two body shells mated togethertaken along section line 3-3 of FIG. 1;

FIG. 4 is a top view of an alternative configuration of a runner system;

FIG. 5 is a top view of a body shell showing an injection deviceinserted in the runner system; and

FIG. 6 is an enlarged view of the area of detail 6 of FIG. 5.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Particular embodiments of the present disclosure will be describedherein with reference to the accompanying drawings. In the followingdescription, well-known functions or constructions are not described indetail to avoid obscuring the present disclosure in unnecessary detail.

Referring now to the drawings, in which like reference numerals identifyidentical or substantially similar parts throughout the several views,FIG. 1 illustrates first body shell 10 having runner system 30 inaccordance with the principles of the present disclosure.

As shown in FIG. 1, first body shell 10 defines side wall 20 about theperimeter of first body shell 10. Side wall 20 has interior surface 22and exterior surface 24. The side wall surface between interior surface22 and exterior surface 24 defines joining surface 26. In any of theembodiments disclosed herein, the runner system can be a recess,channel, or space defined by part of the shell, and is generally narrowand extending the periphery of the chamber of the joined shell parts.

Continuing to refer to FIG. 1, runner system 30 is disposed on joiningsurface 26. Runner system 30 remains between interior surface 22 andexterior surface 24. Runner system 30 diverts around connecting holes15. Runner system 30 has inlet port 32 and outlet port 34 connected bybridge section 36 as shown in FIG. 2. The corners of runner system 30may be generally rounded.

In the embodiment illustrated in FIG. 2, inlet port 32 and outlet port34 each penetrate exterior surface 24 of side wall 20. In anotherembodiment, illustrated in FIG. 4, inlet port 32′ and bridge 36′penetrate an exterior surface 24′ of side wall 20′ while outlet port 34′remains between interior surface 22′ and exterior surface 24′.

Now referring to FIGS. 1 and 3, a particular embodiment of the method isdisclosed, the first step is to provide first body shell 10 and secondbody shell 110. First body shell 10 and second body shell 110 eachhaving joining surfaces 26, 126. Joining surface 26 configured to matewith joining surface 126. The pair of joining surfaces 26, 126 defines apair of mutual joining surfaces.

Runner system 30 is partially disposed within at least one of joiningsurfaces 26, 126. Runner system 30 may be partially disposed within eachjoining surface 26, 126. In this configuration, runner system 30 definesa substantially semi-circular groove on each joining surface 26, 126.

Next, the pair of mutual joining surfaces are aligned such that runnersystem 30 is in contact with each joining surface 26, 126 as shown inFIG. 3.

Once aligned, body shells 10, 110 are secured in position relative toone another. Any known method of securing the body shells together isenvisioned. One known method is to clamp the body shells in position.Another known method is to screw the body shells together usingconnecting holes 15. Another known method is by sonic welding the bodyshells together. Adhesives and other methods can be used.

Once body shells 10, 110 are secured in position, injection device 200is inserted into inlet port 32 such that tip 211 of injection device 200is past bridge section 36 as shown in FIGS. 5 and 6. Injection device200 includes distal portion 210 insertable into inlet port 32. Distalportion 210 includes a lumen in fluid communication with an opening inthe tip 211 for delivering material. Distal portion 210 is fluidlycoupled to a source of material (e.g., the elastomer material). Thesource can be a reservoir of elastomer material or a cartridge.Injection devices are well known to a person skilled in the art andinclude needles and other suitable devices.

After injection device 200 is inserted, an elastomer material (notshown) is injected from injection device 200 through tip 211 into inletport 32. The Elastomer material may be a natural rubber, a syntheticrubber, a silicone that is room temperature vulcanizing (RTV), or anysuitable material with the viscosity to flow through the runner systemfilling all voids before flowing from the outlet port.

When the elastomer material is injected through runner system 30, theelastomer material flows from inlet port 32 through runner system 30towards outlet port 34. When the elastomer material flows from outletport 34, injection device 200 is removed from inlet port 32 whilecontinuing to inject the elastomer material. Injection device 200 isremoved slowly to allow the elastomer material to fill outlet port 34and bridge section 36. This is done to ensure that there are no voids inrunner system 30. Thus, the elastomer material completely fills runnersystem 30.

When runner system 30 is filled with the elastomer material, theelastomer material is cured or allowed to cure. After the elastomermaterial is cured, the elastomer material forms a seal or barrierbetween exterior surfaces 24, 124 and interior surfaces 22, 122 forminghousing chamber 80 within body shells 10, 110 illustrated in FIG. 3. Thematerial may cure on its own, or using heat, UV light, etc.

In an embodiment of the method, the elastomer material also forms a bondbetween body shells 10, 110, further attaching the first and second bodyshells.

In any of the embodiments disclosed herein, the elastomer material hassimilar expansion and contracting properties to the materials of bodyshells 10, 110 such that during an autoclave process, the elastomermaterial and the body shell material expand and contract atsubstantially the same rate maintaining a barrier between housingchamber 80 and exterior surfaces 24, 124.

In any of the embodiments, runner system 30 is comprised of a halfcylindrical groove in each joining surface 26, 126 such that whenjoining surfaces 26, 126 are aligned runner system 30 is substantiallycylindrical, illustrated in FIG. 3.

It is envisioned that this method may be used for instruments with aplurality of body shells having a plurality of pairs of mutual joiningsurfaces having a plurality of runner systems. It is envisioned thateach runner system may be injected either sequentially with respect toother runner systems or simultaneously with respect to other runnersystems or a combination of sequential and simultaneous injection. Inany of the embodiments disclosed herein, one or more chambers 80 can beformed so that components in the chambers are separately sealed from theexterior of the instrument, as well as each other.

While several embodiments of the disclosure have been shown in thedrawings and/or discussed herein, it is not intended that the disclosurebe limited thereto, as it is intended that the disclosure be as broad inscope as the art will allow and that the specification be read likewise.Therefore, the above description should not be construed as limiting,but merely as exemplifications of particular embodiments. Differentembodiments of the disclosure may be combined with one another based onthe particular needs of the patients to achieve optimal results of thesurgical procedures. Those skilled in the art will envision othermodifications within the scope and spirit of the claims appended hereto.

What is claimed is:
 1. A method for assembling and sealing a reusableelectrical surgical instrument, comprising: providing at least two bodyshells of an instrument, each body shell having at least one joiningsurface, where a pair of mutual joining surfaces is defined by thejoining surface one body shell that is configured to mate with thejoining surface of a second body shell, at least one joining surface ofthe pair of mutual joining surfaces having a runner system surroundingthe perimeter substantially near the edge, the runner system having aninlet port and an outlet port connected by a bridge section; aligningthe pair of mutual joining surfaces; securing the body shells inposition relative to each other; inserting an injection device into theinlet port past the bridge section; injecting an elastomer material fromthe injection device through the inlet port until the elastomer materialexits from the outlet port; removing the injection device from the inletport while continuing to inject elastomer material from the injectiondevice; and curing the elastomer material forming a seal along the pairof mutual joining surfaces.
 2. The method of claim 1, wherein the runnersystem is on both joining surfaces of the pair of mutual joiningsurfaces.
 3. The method of claim 2, wherein the runner system forms agroove on the joining surface.
 4. The method of claim 1, wherein thestep of curing further comprises the elastomer material forming a bondwith the first and second body shells along the pair of mutual joiningsurfaces.
 5. The method according to claim 1, wherein the body shellsare secured together by at least one of the methods of screwing, sonicwelding, or clamping.
 6. The method according to claim 1, wherein theelastomer material is from the group consisting of natural rubber,synthetic rubber, and room temperature vulcanization.
 7. A methodaccording to claim 1, wherein more than two body shells are provided,each body shell having at least one joining surface, where each joiningsurface of a body shell is configured to mate with the joining surfaceof second body shell forming a plurality of mutual joining surfaces. 8.The method according to claim 7, wherein each runner system is injectedsequentially.
 9. The method according to claim 7, wherein each runnersystem is injected simultaneously.